Effect pigments based on coated glass flakes

ABSTRACT

The present invention relates to effect pigments based on thin glass flakes and to a method for the production of such pigments. The resulting pigment can be used in any application for which pearlescent pigments have been heretofore used such as, for example, in plastics, paints, inks, cosmetic formulations, coatings including solvent or waterborne automotive paint systems, powder coatings, inks and agriculture foils.

This application is a divisional of U.S. application Ser. No. 10/473,710 filed on Nov. 10, 2003, which is incorporated entirely by reference herein.

The present invention relates to effect pigments based on thin glass flakes, to a method for the production of such pigments and their use in plastics, paints, coatings, powder coatings, inks, printing inks, glasses, ceramic products, agriculture foils, and in cosmetic formulations.

Since more than 40 years iridescent luster effects can be achieved using so called nacreous or pearlescent pigments. Various alternative techniques have been developed to create colour/lustre effects. The most important, economic and common way to make these pigments is to coat a platelet shaped carrier with high refractive substances like TiO₂, Fe₂O₃, SnO₂, ZrO₂, Cr₂O₃ or combinations of these or with alternating layers of high and/or low refractivity. So far the nearly exclusively used carrier is wet ground muscovite mica. It is cheap, readily available and easy to cleave into smooth and very thin platelets. These can be classified into any desired particle size distribution. Additionally, pigments based on mica are very stable towards chemical, mechanical or thermal treatment. But there are some disadvantages of mica, since it is a natural product and shows inconsistencies from source to source and even from batch to batch. This has to be overcome by adjusting the processing parameters. Natural mica contains impurities like quartz which makes the processing more complicated (abrasion of grinding tools, waste) or like Fe, Mn, Cu which makes the masstone yellowish grey rather than white. When ground it yields platelets showing a broad distribution of thicknesses and diameters. This can be reduced by proper classification but will never lead to uniform shape.

In the past researchers tried to find corresponding alternatives to mica which keep the advantages of it but did not contain the above mentioned disadvantages.

A wide variety of other platy materials have been proposed as substitute for mica in the patent literature. These include non-soluble inorganic materials such as glass, enamel, china clay, porcelain, natural stones or other silicaceous substances, metal objects and surfaces of organic polymer materials such as polycarbonate as disclosed for example in U.S. Pat. Nos. 3,123,485, 3,219,734, 3,616,100, 3,444,987, 4,552,593 and 4,735,869. While glass has been mentioned as a possibility on many occasions, for instance in U.S. Pat. No. 3,331,699, commercial pearlescent products are not made using glass and experience has shown that products made using glass as the platelet substrate have rather poor quality.

U.S. Pat. No. 3,331,699 discloses that glass flakes may be coated with a translucent layer of particles of a metal oxide having a high index of refraction, such as titanium dioxide, provided there is first deposited on the glass flakes a nucleating substance which is insoluble in the acidic solution from which the translucent layer of metal oxide is deposited. The patent does not mention the necessity of a smooth transparent film, not particles, being necessary for quality interference pigments to be developed. The patent teaches that the nature of the glass is not critical, but that the presence of the nucleated surface is critical. It is further stated that there are only a small number of metal oxide compounds which are insoluble in the acidic solution and capable of forming a nucleated surface on the glass flakes; tin oxide and a fibrous boehmite form of alumina monohydrate are the only two such materials disclosed. As demonstrated in the examples below, products prepared according to the teachings of this patent are poor in quality.

U.S. Pat. No. 5,436,077 teaches a glass flake substrate which has a metal covering layer on which is formed a dense protective covering layer of a metal oxide such as titanium dioxide. In this patent, the nature of the glass is unimportant, the metallic coating provides the desired appearance and the overcoating of the metal oxide is present to protect the metallic layer from corrosive environments.

EP 0 912 640 B1 teaches the coating of thick flakes of C glass having a first coating comprising iron oxide or rutile titanium dioxide thereon. The disadvantage of C glass is the limited thermal stability. As disclosed in the EP 0 912 640 B1 the rutile pigments prepared according to the corresponding examples were calcined at temperatures not higher than 600° C. It is well known that the calcining temperature is of essential importance for the stability of rutile pigments, especially for outdoor applications. To yield sufficiently stabilized rutile TiO₂ layers on a substrate calcining temperatures of at least 800° C. are requested.

For the preparation of pearlescent pigments the transparency and the thickness of the platy substrate are very important. For the first time

EP 0 289 240 B1 discloses the manufacturing of extremely thin glass flakes at reasonable costs. According to the claimed process the glass flakes cannot be only made in any desired composition, e. g., from pure SiO₂, but also in any thickness tailored for the application wanted down to below 0.8 μm.

It is an object of the present invention to overcome the problems of the prior art and to provide novel effect pigments which have advantageous application properties. This object is achieved by the inventive effect pigments based on very thin glass flakes having the following characteristics:

(1) thickness of the glass flakes ≦1.0 μm

(2) high temperature and mechanical stability

(3) smooth surfaces

The present invention relates to effect pigments based on glass flakes with a thickness of ≦1.0 μm coated with one or more layers with a high and/or a low reflective index. The thickness of the glass flakes is preferably ≦0.8 μm and especially ≦0.5 μm. Especially preferred are thin glass flakes with a softening point ≧800° C.

Glass can be classified for example as A glass, C glass, E glass, ECR glass. For the present invention quartz glass is preferred but the production of this glass is very expensive. Glass types which fulfill the feature of the requested softening point are quartz glass, and any other glass composition having a softening point of ≧800° C. Glass flakes which fulfill the requirements are special glasses like e. g. Schott Duran or Supremax types The softening point in the present invention is defined, according to ASTM C 338 as the temperature at which a uniform fiber of glass with a diameter of 0.55-0.75 mm and a length of 23.5 cm increases its length by 1 mm/min when the upper 10 cm is heated at a rate of 5° C./min.

Suitable glass flakes preferably prepared according to EP 0 289 240 B1 are characterized in that they contain an average particle size in the range of 5-1000 μm, preferably in the range of 5-150 μm. Preferred glass flakes have an average particle size in the range of 5-150 μm and a thickness of 0.1-0.5 μm, preferably of 0.1-0.3 μm. The aspect ratio of glass flakes is in the range of 10-300, preferably in the range of 50-200.

The glass particles can be coated with one or more layers selected from the group consisting of metal oxides, metal suboxides, metal fluorides, metal oxyhalides, metals chalcogenides, metal nitrides, metal sulfides, metal carbides, or mixtures thereof.

Examples of suitable metal oxides are TiO₂, Fe₂O₃, TiFe₂O₅, Ti suboxides, Fe₃O₄, Cr₂O₃, Al₂O₃, SiO₂, ZrO₂, ZnO, SnO₂, CoO, Co₃O₄, VO₂, V₂O₃, Sn(Sb)O₂ or mixtures thereof. The TiO₂ layer can be in the rutile or anatase modification, preferably the TiO₂ layer is rutile. Especially preferred are glass flakes coated with TiO₂ and/or Fe₂O₃.

Metal sulfide coatings on glass flakes are preferably selected from sulfides of tin, silver, lanthanum, rare earth metals, preferably cerium, chromium, molybdenum, tungsten, iron, cobalt and/or nickel.

The glass flakes can be coated in the same way as e. g. mica based pearl lustre pigments. Coatings with a metal oxide may be accomplished by any known methods, such as hydrolysis of a metal salt by heating or alkali, which deposits hydrated metal oxide, optionally followed by calcination.

In general, the procedure involves the dispersing of the thin glass flake particles and combining that dispersion with a precursor which forms a hydrous metal oxide film coating on the flakes.

After the glass is dispersed in water and placed in an appropriate vessel, the appropriate metal salts are added. The pH of the resulting dispersion is maintained at an appropriate level during the addition of the metal salts by simultaneous feeding a suitable base, for example sodium hydroxide, to cause precipitation of the hydrous metal dioxide on the glass flakes. An aqueous acid, for example hydrochloric acid, can be used for adjusting the pH. The coated platelets can, if desired, be washed and dried before being calcined to the final pigment. The procedure is described in detail in U.S. Pat. No. 5,433,779 and in the German Patents 14 67 468, 19 59 998, 20 09 566, 22 14 545, 22 15 191, 22 44 298, 23 13 331, 25 22 572, 31 37 808, 31 37 809, 31 51 343, 31 51 354, 31 51 355, 32 11 602 and 32 53 017.

The effect pigments of the present invention are preferably prepared by wet-chemically coating of the glass flakes or by gas phase decomposition of volatile metal compounds (CVD, PVD) or electroless plating.

The effect pigments obtained in this way are characterized in that one or more homogeneous layers enrobing the uniform thin glass flakes.

Preferred effect pigments of the present invention are given in the following:

-   glass flake+TiO₂ (rutile) -   glass flake+Fe₂O₃ -   glass flake+Fe₃O₄ -   glass flake+TiFe₂O₅ -   glass flake+Cr₂O₃ -   glass flake+ZrO₂ -   glass flake+Sn(Sb)O₂ -   glass flake+BiOCI -   glass flake+Al₂O₃ -   glass flake+Ce₂S₃ -   glass flake+MoS₂

In general, the layer thickness ranges from 0.1 to 1000 nm, preferably from 0.2 to 300 nm. The optical layer thickness will in general be adapted to the particular application. Preferred pigments are coated with one or two layers.

To enhance the light and weather stability it is frequently advisable, depending on the field of application, to subject the coated glass flakes to a surface treatment. Useful surface treatments include for example the processes described in DE-C 22 15 191, DE-A 31 51 354, DE-A 32 35 017 or DE-A 33 34 598, DE 40 30 727 A1, EP 0 649 886 A2, WO 97/29059, WO 99/57204, U.S. Pat. No. 5,759,255. This surface treatment further enhances the chemical stability of the pigments and/or facilitates the handling of the pigment, especially its incorporation into various application media.

The effect pigments of the present invention are advantageous useful for many purposes, such as the coloring of plastics, glasses, ceramic products, agriculture foils, decorative cosmetic formulations and in particular coatings, especially automotive coatings, and inks, including printing inks. All customary printing processes can be employed, for example offset printing, intaglio printing, bronze printing, flexographic printing. Furthermore they can be used as functional pigments like conductive pigments, as magnetic pigments or to make media, for example plastics, board products and papers, laser-markable.

The effect pigments of the present invention are also advantageously useful for these applications in admixture with filler pigments or transparent and hiding white, colored and black organic and inorganic pigments and also with conventional transparent, colored and black luster pigments based on metal oxide coated mica, TiO₂ flakes, SiO₂ flakes or Al₂O₃ flakes and coated or uncoated metal pigments, BiOCI pigments, platelet shaped iron oxides, or graphite flakes.

Additionally, the inventive pigment mixtures can contain organic or inorganic colourants, thixotropy agents, wetting agents, dispersing agents, water, organic solvent or solvent mixtures, etc.

The pigment mixtures of the invention are simple and easy to handle. The pigment mixtures can be incorporated into the system in which it is used by simple mixing. Laborious milling and dispersing procedures for the pigments are not necessary.

The coated glass flakes of the invention can be used for pigmenting and/or coating materials, printing inks, plastics, agricultural films, button pastes, for the coating of seed, for the colouring of food, coatings of foods, medicaments or cosmetic formulations. The concentration of the pigments in the system in which it is to be used for pigmenting is generally between 0.01 and 50% by weight, preferably between 0.1 and 5% by weight, based on the overall solids content of the system. This concentration is generally dependent on the specific application.

Plastics comprising the pigment mixture of the invention in amounts of 0.1 to 50% by weight, in particular from 0.5 to 7% by weight, are frequently notable for a particular brilliance.

In the coating sector, especially in automotive finishing, the glass flakes are employed in amounts of 0.5 to 10% by weight.

In the pigmentation of binder systems, for example for paints and printing inks for intaglio, offset or screen printing, the pigment is incorporated into the printing ink in amounts of 2-50% by weight, preferably 5-30% by weight and in particular 8-15% by weight.

The invention likewise provides pigment preparations comprising coated glass flakes, optionally effect pigments, binders and, if desired, additives, the said preparations being in the form of substantially solvent-free, free-flowing granules. Such granules contain up to 95% by weight of the inventive pigments. A pigment preparation in which the glass flakes of the invention are pasted up with a binder and with water and/or an organic solvent, with or without additives, and the paste is subsequently dried and brought into a compact particulate form, e. g. granules, pellets, briquettes, a masterbatch or tablets, is particularly suitable as a precursor for printing inks.

The present invention therefore also provides formulations containing the pigments of the invention.

In order to further illustrate the invention, various non-limiting examples are set forth below. In these, as well as throughout the balance of this specification and claims, all parts and percentages are by weight and all temperatures are in degrees centigrade unless otherwise indicated.

EXAMPLES Example 1 (Rutile Silver Pigment) Prior Art

200 g flakes of E-glass (thickness: 5 μm; diameter: 10-40 μm; specific surface area: approximately 0.2 m²/g) are suspended in 2 l of deionized water. With vigorous stirring the suspension is heated to 80° C. After having adjusted the pH to 2.0 with dilute HCl a first layer of SnO₂ is precipitated onto the glass flakes by feeding a solution of 3 g SnCl₄×5 H₂O (in 10 ml conc. HCl plus 50 ml of DI water) into the suspension under simultaneous neutralization with 10% NaOH over a period of about 1 h. To complete the reaction the suspension is kept stirring for another 15 min. The coating is continued by adjusting the pH to 1.8 with dilute HCl and then titrating 63.5 ml of TiCl₄-solution (400 g TiCl₄/l DI water) against 10% NaOH over a period of about 3 h. Having reached the desired layer thickness the coating is stopped, stirred for another 15 min, filtered, washed with DI water and dried. After calcination at 800° C. for 30 min a silverwhite rutile pigment is yielded.

Example 2 Rutile Silver Pigment

200 g flakes of E-glass (thickness: 0.5 μm; diameter: 10-40 μm; specific surface area: approximately 1.7 m²/g) are suspended in 2 l of DI water. The coating is carried out the same way as in example 1. Titration periods keep the same, only the amounts of solutions are adjusted to the different base material:

-   5 g SnCl₄×5 H₂O (in 15 ml conc. HCl plus 75 ml DI water) -   196.3 ml of TiCl₄ solution (400 g TiCl₄/l DI water)

After calcination at 800° C. for 30 min a brilliant silverwhite rutile pigment is yielded.

Examples 3 and 4 Rutile Interference Green Pigment

The coatings are started in the same ways as for examples 1 and 2, only the amount of TiO₂ (400 g TiCl₄/l DI water) coated was increased to yield green interference type pigments. The further steps are again carried out as described in examples 1 and 2.

To evaluate their properties draw down cards are made from all of these pigments. Additionally sprayed panels were prepared. The pigments based on glass flakes with a thickness of 5.0 μm and 0.5 μm are checked for their coloristics and their visual performance.

Results: draw downcards and panels pigments with a thickness of 5.0 μm showed very weak performance making a “dilute” impression. For the silver little brilliance and little hiding effect was observed while for the green a dull colour and little brilliance are found;

-   -   a little better is the effect in the sunlight as some larger         flakes show a kind of sparkle;     -   completely different is the situation with a thickness of 0.5 μm         pigments: They exceeded comparable mica pigments regarding         brilliance, luster and (for the green) chroma;     -   particularly impressing is the high transparency combined with         clear color;     -   looking with the microscope shows that the surfaces of all         pigments are well and uniformly coated and that the differences         result mostly from the imperfect orientation of the 5 μm         particles; 

1-12. (canceled)
 13. Effect pigments comprising glass flakes with a thickness of ≦1.0 μm, which glass flakes are coated with one or two layers of TiO₂ in the rutile modification, Fe₂O₃, TiFe₂O₅, Ti suboxides, Fe₃O₄, Cr₂O₃, Al₂O₃, SiO₂, ZrO₂, ZnO, SnO₂, CoO, Co₃O₄, VO₂, V₂O₃, Sn(Sb)O₂ or mixtures thereof to form said effect pigments.
 14. Effect pigments according to claim 13, wherein the softening point of the glass flakes is ≧800° C.
 15. Effect pigments according to claim 13, wherein the metal oxide is TiO₂ in the rutile modification.
 16. Effect pigments according to claim 15, characterized in that the glass flakes are coated with TiO₂ in the rutile modification, Fe₂O₃ or a mixture of TiO₂ in the rutile modification and Fe₂O₃.
 17. Effect pigments according to claim 13, wherein the glass flakes are coated with one layer.
 18. A method of preparing effect pigments according to claim 13, comprising coating the glass flakes by wet chemical coating, by chemical or physical vapor deposition or electroless plating and optionally calcining the coated glass flakes.
 19. A product selected from the group consisting of plastics, coatings, powder coatings, paints, inks, printing inks, glasses, ceramic products, agriculture foils and cosmetic formulations, comprising effect pigments according to claim 13 and a carrier.
 20. A product selected from the group consisting of conductive pigments, magnetic pigments and dopants for the laser-marking of papers and plastics, comprising effect pigments according to claim
 13. 21. A pigment formulation containing the effect pigments according to claim 13 and a carrier.
 22. Effect pigments according to claim 13, which are as follows: glass flake+TiO₂ (rutile) glass flake+Fe₂O₃ glass flake+Fe₃O₄ glass flake+TiFe₂O₅ glass flake+Cr₂O₃ glass flake+ZrO₂ glass flake+Sn(Sb)O₂ glass flake+BiOCI glass flake+Al₂O₃ glass flake+Ce₂S₃ or glass flake+MoS₂.
 23. Effect pigments according to claim 13, which are as follows: glass flake+Fe₂O₃ glass flake+Fe₃O₄ glass flake+TiFe₂O₅ glass flake+Cr₂O₃ glass flake+ZrO₂ glass flake+Sn(Sb)O₂ glass flake+BiOCI glass flake+Al₂O₃ glass flake+Ce₂S₃ or glass flake+MoS₂.
 24. Effect pigments according to claim 13, which are as follows: glass flake+TiO₂ (rutile).
 25. Effect pigments according to claim 13, wherein the glass have a thickness of ≦0.8 μm.
 26. Effect pigments according to claim 25, which are as follows: glass flake+TiO₂ (rutile) glass flake+Fe₂O₃ glass flake+Fe₃O₄ glass flake+TiFe₂O₅ glass flake+Cr₂O₃ glass flake+ZrO₂ glass flake+Sn(Sb)O₂ glass flake+BiOCI glass flake+Al₂O₃ glass flake+Ce₂S₃ or glass flake+MoS₂.
 27. Effect pigments according to claim 13, wherein the glass have a thickness of ≦0.5 μm.
 28. Effect pigments according to claim 27, which are as follows: glass flake+TiO₂ (rutile) glass flake+Fe₂O₃ glass flake+Fe₃O₄ glass flake+TiFe₂O₅ glass flake+Cr₂O₃ glass flake+ZrO₂ glass flake+Sn(Sb)O₂ glass flake+BiOCI glass flake+Al₂O₃ glass flake+Ce₂S₃ or glass flake+MoS₂.
 29. Effect pigments according to claim 13, wherein the glass flakes are quartz glass.
 30. Effect pigments according to claim 13, wherein the glass flakes are amorphous glass. 